I'm not sure if I'm the only one facing this issue, but would definitely love to hear suggestions. I have an HK 500 GT, with Typhoon 500 motor, 70 Amp HK ESC with BEC, 6 cell, 3000mAH Lipo (Tried and puffed 2 turnigy Nano-Tech packs with rating of 35-70 C). The motor runs HOT, along with ESC and the battery pack.

I have a 12 tooth pinion, and the belt tension is reasonable, the meshing of gears also havs fair amount of play, so not too tight a mesh.

Any suggestions on what could be the issue on this one, as I have recently bought a Zippy, 2650 Mah, 40C pack and am concerned if this would stand the load or not.

I have the same heli with a similar setup. How long are your flight times? The lipo is under increased strain as the voltage drops. If you are a 3D flyer it will surely be harder on your packs than regular sport flying.

I fly my packs in both airplanes and helis only down to about 3.7 - 3.8 volts per cell. In my helis that translates to about 5-6 minutes of flight time. In my experience it helps with longevity of my lipos.